Harmonic Distortion - Issues and Solutions

Harmonic Distortion of Drives: Issues and Solutions
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Part 1:
1.1 Training on harmonics: Basics
1.2 Training on harmonics: Problems and issues
1.3 The impact of the short circuit power ratio
Part 2:
2.1 Harmonic solutions available

2.2 Passive Harmonic Filter technologies
2.3 Hybrid Harmonic Filter
2.4 Open Discussion
Harmonics
What is a Harmonic?
Power Quality - distortion
Reactive current on fundamental frequency Voltage unbalance
Transients Harmonic distortion

Power Quality - non-linear loads
Rectifier with no/low inductance Rectifier with ~4% inductance Mix of non-linear loads
Current shape is significantly Current shape is significantly High distortion: The current shape
different from sinus. Significant different from sinus, but is extremely different from sinus.
distortion. fundamental part is significantly
higher than without choke.
Typical equipment: 6-Pulse rectifier Typical equipment: 6-Pulse rectifier Typical equipment: mix of single
without inductance. (e.g.: low with 4% DC-inductance. (e.g.: phase and 6-Pulse rectifier without
power or low quality drives) quality drives) inductance.
Harmonics - composed frequencies
Spectrum Individual frequencies Composed frequencies
Fundamental frequency
+ 3rd Harmonic
+ 3rd Harmonic
+ 5th Harmonic
Harmonic distortion - evaluation of harmonics
The harmonic frequency is defined by:

(𝑛 = harmonic number)
𝑓ℎ = 𝑛 • 𝑓𝑢𝑛𝑑𝑎𝑚𝑒𝑛𝑡𝑎𝑙 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
Example for 𝑛 = 11 (11th harmonic) in a 50Hz network:

𝑓ℎ11 = 11 • 50Hz = 550Hz
The harmonic current is the amplitude value of the corresponding frequency.

𝐼ℎ11 = current amplitude of the 550Hz signal
Harmonics - mathematical basic
Fourier transform
- Any signal can be expressed as a sum of its harmonics.

- Harmonics are multiples of the fundamental frequency.
Examples for 50Hz:
- 2nd Harmonic = 100Hz
- 3rd Harmonic = 150Hz
…
- 5th Harmonic = 250Hz
…
…
…
…
- The Fourier transform decomposes a function of

time (a signal) into its individual frequencies
Reference: www.wikipedia.de
Harmonics
What is a Harmonic?
Harmonics are sinewave signals overlapping the main (fundamental)

frequency.
Every Harmonic is defined by:
Harmonic order (5th Harmonic = 250Hz, 7th Harmonic = 350Hz … )

Harmonic amplitude (how strong is the harmonic)
Harmonic angle (harmonics of different angle compensate each other)
How are Harmonics evaluated?

THDi and THDv value

The harmonic distortion is evaluated by the “Total Harmonic Distortion” (THD). This is
separated into THDv (or THDu) for voltage distortion and THDi for current distortion.
This is typically defined for harmonics up to 40th or 50th.
Flashback: what is the IRMS
IRMS = σ𝑛=40 2
𝑛=1 𝐼𝑛 =
2
𝐼ℎ1 2
+ 𝐼ℎ2 2
+ 𝐼ℎ3 2
+ 𝐼ℎ4 2
+ 𝐼ℎ5 2
+ 𝐼ℎ6 2
+ ⋯ + 𝐼ℎ40
Fundamental part Harmonic part

THDi
The sum of all harmonic currents up to the 40th, are defined as THC
𝑛=40
2 2 2 2 2 2
𝑇𝐻𝐶 = ෍ 𝐼𝑛2 = 𝐼ℎ2 + 𝐼ℎ3 + 𝐼ℎ4 + 𝐼ℎ5 + 𝐼ℎ6 + ⋯ + 𝐼ℎ40
𝑛=2
The THDi is defined as:

𝑇𝐻𝐶
𝑇𝐻𝐷𝑖 = • 100%
𝐼1
Hence:
σ𝑛=40 2 2 +𝐼 2 +𝐼 2 +𝐼 2 +𝐼 2 +⋯ +𝐼 2
𝐼ℎ2
𝑛=2 𝐼𝑛 ℎ3 ℎ4 ℎ5 ℎ6 ℎ40
𝑻𝑯𝑫𝒊 = • 100% = • 100%
𝐼1 𝐼1
THDv
σ𝑛=40 2 2 +𝑣 2 +𝑣 2 +𝑣 2 +𝑣 2 +⋯ +𝑣 2
𝑣ℎ2
𝑛=2 𝑣𝑛 ℎ3 ℎ4 ℎ5 ℎ6 ℎ40
𝑻𝑯𝑫𝒗 = • 100% = • 100%
𝑣1 𝑣1
Harmonic distortion - typical measurement
Drive input current

Harmonics
How are Harmonics evaluated?
Harmonic current distortion is evaluated by the THDi (or TDD = Total Demand Distortion)
This is the harmonic content of the IRMS (measured current) divided by the fundamental part
Harmonic voltage distortion is evaluated by the THDv

This is the harmonic content of the vRMS (measured voltage) divided by the fundamental part
Part 1:
1.3 The impact of the short circuit power ratio
Part 2:

2.4 Open Discussion
Harmonics
Simple! That’s it?

Harmonic distortion of motors / VFD
THDi1 THDi2 THDi3 THDi4 THDi4 THDi0

103% 52% 35% 3,5%-10% 3-5% 1-3%
IRMS + 55%
IRMS + 12%
IRMS + >10%
IRMS + 7%
Passive Passive
IRMS + 0%
IRMS + 0%
uk==2%* uk==4%* HF LCL
HF HF
VFD VFD VFD VFD AFE
M M M M M M
*choke can be added AC or DC side with similar result. Typically installed DC side.
Harmonics
Simple! That’s it?
No!
Using THDi as an evaluation for harmonics, gives you quick picture of the harmonic situation.
Looking at the THDi equation, all Harmonic orders are equal. They are not!
2 +𝐼 2 +𝐼 2 +𝐼 2 +𝐼 2 +⋯ +𝐼 2
𝐼ℎ2 ℎ3 ℎ4 ℎ5 ℎ6 ℎ40
𝑻𝑯𝑫𝒊 = • 100%
𝐼1
Harmonics
Why do we care about Harmonic currents?

Harmonic distortion - ideal supply
Ideal supply
• Generators produce ideal sinusoidal current.

• Transformers and wires don’t have
any impedance
• The Loads are consuming ideal sinus current
• --> No voltage distortion
ELTROPLAN-REVCON – company profile

Harmonic distortion - real supply
Real supply
• Generators produce (almost) ideal sinusoidal current.

• The Loads are consuming non linear current
• --> voltage distortion Ohm´s Law
V=I•Z
(Harmonics are not filtered by a transformer but transferred to the next voltage level)
Harmonics
Why do we care about Harmonic currents?
Due to:
V=I•Z
all harmonic currents cause voltage distortion
Voltage Distortion affects all equipment connected

Harmonics
Are all Harmonics equal?

Harmonic distortion of motors / VFD
THDi1 THDi2 THDi3 THDi4 THDi4 THDi0

103% 52% 35% 3,5%-10% 3-5% 1-3%
Passive Passive
uk==2%* uk==4%* HF LCL
HF HF
VFD VFD VFD VFD AFE
M M M M M M
*choke can be added AC or DC side with similar result. Typically installed DC side.
Harmonic distortion - comparison
Standard Drive vs. Slim DC Bus Drive

500 100 500 50,0
400 80,0 400 40,0
300 60,0 300 30,0
200 40,0 200 20,0
100 20,0 100 10,0
V 0,00 A V 0,00 0,00 A
0,00
-100 -100 -10,0
-20,0
-200 -200 -20,0
-40,0
-300 -300 -30,0
-60,0
-400 -400 -40,0
-80,0
-500 -500 -50,0
-100
20.12.2018 19,992 (ms) 20.12.2018 04.06.2019 19,996 (ms) 04.06.2019
17:18:43.106 Wellenform A1
3 ms/Div 17:18:43.126 14:36:48.128 Wellenform A1
3 ms/Div 14:36:48.148
72,17 Arms, 31,10 %THD 34,63 Arms, 31,17 %THD

100 100
80 80
60 60
40 40
20 20
0 0
1 5 10 15 20 25 30 35 40 45 50 1 5 10 15 20 25 30 35 40 45 50
The THD is a good evaluation for Harmonic Distortion but it is not sufficient to give a full
evaluation of the problems that may be caused by harmonics.
Example:
100A distortion on the 5th Harmonic (I5=100A)
will cause the same THDi as:
100A distortion on the 37th Harmonic (I37=100A),
Power loss inside a transformer caused by I37

would be significantly higher.
Power loss inside a motor caused by I37 would be

significantly higher.
And so on…
IEC define PWHD

The Partial Weighted Harmonic Distortion is a value to evaluate the higher harmonics
between the 14th and 40th. This evaluation is available for current (PWHD,i)
and voltage (PWHD,v) and is used in several standards.
σ𝑛=40 2 2 2 2 2 2
𝑛=14 𝐼𝑛 𝐼ℎ14 + 𝐼ℎ15 + 𝐼ℎ16 + 𝐼ℎ17 + ⋯ + 𝐼ℎ40
𝑷𝑾𝑯𝑫, 𝒊 = • 100% = • 100%
𝐼1 𝐼1
σ𝑛=40 2 2 2 2 2 2
𝑛=14 𝑈𝑛 𝑈ℎ14 + 𝑈ℎ15 + 𝑈ℎ16 + 𝑈ℎ17 + ⋯ + 𝑈ℎ40
𝑷𝑾𝑯𝑫, 𝒗 = • 100% = • 100%
𝑈1 𝑈1
Standards - IEEE
IEEE 519-2014
Current distortion level of for systems 120V – 69kV
Harmonics
Are all Harmonics equal?
No. Higher Order Harmonics will typically cause more harm than
lower order harmonics.
Evaluation of Harmonic distortion based on THDi or TDD is only

possible, if the harmonic spectrum is known.
(e.g. Drive load with high performance / high quality drive)
Harmonics
Which damage is caused by harmonics?

Harmonic voltage distortion
Voltage distortion cause power loss!

Comparison of Motors DOL @ equal load but different voltage distortion
18.5kW 18.5kW
THDv = 6,8% THDv = 1,8%
@ 8% THDv, a motor DOL can run max. 85% load

Harmonic distortion - Problems
Transformers and PFC

Increased losses!
Reduced power! Expected lifetime lower!
Transformers and capacitor banks must be oversized
or might overheat at nominal load.
Electronical equipment
Increased losses, and reduced lifetime expectation.
Equipment failures  Lost data, Production stop, Equipment costs
Wrong evaluation of signals  troubleshooting costs and production loss
Harmonic distortion - Problems
Motors and Generators (uncontrolled)

Increased losses, and reduced lifetime expectation.
Reduced torque and unsteady torque (even vibrations) on
shaft output. Lower lifetime expectations of Bearings,
gearboxes and further connected equipment
System Efficiency
Equipment efficiency may be affected by the
harmonic distortion of the mains voltage. In
addition connection wires will produce higher
losses. This leads to higher costs for user.
Harmonics
Which damage is caused by harmonics?

Every non resistive equipment will suffer from Harmonics.
Lower lifetime
Electrical and mechanical damage
Less efficiency
Part 1:
1.3 The IEEE 519 and the impact of the short circuit power ratio
Part 2:

2.4 Open Discussion
Harmonics
Do I need Harmonic mitigation?

21 Standards - Network conditions
The harmonic currents of equipment cause harmonic distortion on the mains voltage.
The impact of the voltage depend on the strength of the mains supply.
Simplified diagrams:
100kVA VFD
50kW
uk=4%
G M
THDv = 3%
THDi = 33%
200kVA
VFD
50kW
uk=4%
G M
THDv = 2.5%
THDi = 36%
Harmonics – Standards and Recommendation
Standard Class THDv limit
EN 50160 - 8%
IEC 61000-2-4 1 5%
IEC 61000-2-4 2 8%
IEC 61000-2-4 3 10%
IEEE 519-2014 <1000V 8%
G5/4 400V 5%
Practice - THDv limit
Good Practive - 5%
IEEE 519-2014 Target - 5%
Standards - IEEE
IEEE 519-2014
Current distortion level of for systems 120V – 69kV
TDD
Total Demand Distortion of the current (used in e.g. IEEE-519:2014)
Equal to THDi the TDD express the distortion of harmonics from 2nd - 40th. But the THC is
divided through IL instead of I1.
IL is also the fundamental frequency amplitude, but defined as the maximum demand
current. IEEE-519: “This current value can be established at the PCC and should be taken
as the sum of the currents corresponding to the maximum demand during each of the
twelve previous months divided by 12.“
σ𝑛=40 2
𝑛=2 𝐼𝑛
2
𝐼ℎ2 2
+ 𝐼ℎ3 2
+ 𝐼ℎ4 2
+ 𝐼ℎ5 2
+ 𝐼ℎ6 2
+ ⋯ + 𝐼ℎ40
𝑇𝐷𝐷 = = • 100%
𝐼𝐿 𝐼𝐿
At full load: TDD = THDi

Harmonic distortion - TDD vs. THDi
Looking at THDi only, an Inexperienced user, might think that 18% load is worst case harmonic distortion.
TDD is user friendly as always taking reference to the maximum current and showing worst case harmonic
distortion (here 120% load).
Standards - Network conditions
𝑆𝑆𝐶 𝐼𝑆𝐶 𝑅𝑆𝐶𝐸 : 𝑆ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑖𝑡 𝑝𝑜𝑤𝑒𝑟 𝑟𝑎𝑡𝑖𝑜

𝑅𝑆𝐶𝐸 = ≈
𝑆𝑒𝑞𝑢 𝐼𝐿
𝑆𝑆𝐶 : 𝑆ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
𝐼𝑆𝐶 : 𝑆ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡
2
𝑈𝑛𝑜𝑚
𝑆𝑆𝐶 = 𝑆𝑒𝑞𝑢 : 𝐸𝑞𝑖𝑝𝑚𝑒𝑛𝑡 𝑝𝑜𝑤𝑒𝑟
𝑍𝑠𝑐
𝐼𝐿 : 𝐿𝑜𝑎𝑑 𝑐𝑢𝑟𝑟𝑒𝑛𝑡
𝑍𝑠𝑐 : 𝑆ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑖𝑡 𝑖𝑚𝑝𝑒𝑑𝑎𝑛𝑐𝑒 (50Hz)

𝑍𝑠𝑐 = 2
𝑅𝑠𝑐 + 2
𝑋𝑠𝑐
Standards - short circuit power calculation
𝒁𝒔𝒄 : 𝑺𝒉𝒐𝒓𝒕 𝒄𝒊𝒓𝒄𝒖𝒊𝒕 𝒊𝒎𝒑𝒆𝒅𝒂𝒏𝒄𝒆 (50Hz)
2
𝑈𝑙𝑣 𝑢𝑥 𝑋𝑠𝑐,𝑙𝑣 = 𝜔 • 𝐿𝑤𝑖𝑟𝑒
𝑅𝑠𝑐,𝑚𝑣 ≈ 0 → 𝑋𝑠𝑐,𝑚𝑣 ≈ 𝑍𝑠𝑐,𝑚𝑣 𝑋𝑠𝑐,𝑡 = • (𝐿𝑤𝑖𝑟𝑒 based on spez. inductance and length)
𝑆𝑡 100%
2
𝑋𝑠𝑐,𝑚𝑣 =
𝑈𝑙𝑣
* 2 𝑅𝑠𝑐,𝑙𝑣
𝑆𝑚𝑣
𝑈𝑙𝑣 𝑢𝑟 (𝑅𝑠𝑐,𝑙𝑣 based on spez. resistance and length)
𝑅𝑠𝑐,𝑡 = •
𝑆𝑡 100%
2 + 𝑋2 = 2 2
𝑍𝑠𝑐 = 𝑅𝑠𝑐 𝑠𝑐 𝑅𝑠𝑐,𝑡 + 𝑅𝑠𝑐,𝑙𝑣 + 𝑋𝑠𝑐,𝑚𝑣 + 𝑋𝑠𝑐,𝑡 + 𝑋𝑠𝑐,𝑙𝑣
*low voltage value must be used in order to add up the Impedance values!
Standards - short circuit power estimation
𝒁𝒔𝒄 : 𝑺𝒉𝒐𝒓𝒕 𝒄𝒊𝒓𝒄𝒖𝒊𝒕 𝒊𝒎𝒑𝒆𝒅𝒂𝒏𝒄𝒆 (50Hz)

(simplified calculation based on transformer impedance)
2
𝑋𝑠𝑐,𝑚𝑣 = 0 𝑈𝑙𝑣 𝑢𝑥 𝑋𝑠𝑐,𝑙𝑣 = 0
𝑋𝑠𝑐,𝑡 = •
𝑆𝑡 100%
𝑅𝑠𝑐,𝑚𝑣 = 0 𝑅𝑠𝑐,𝑙𝑣 = 0
2
𝑈𝑙𝑣 𝑢𝑟
𝑅𝑠𝑐,𝑡 = •
𝑆𝑡 100%
𝑆𝑇
𝑆𝑠𝑐,𝑡 = • 100% =
𝑢𝑘
Harmonics
Do I need Harmonic mitigation?
Good Practice
Transformer Load % Non-linear Load Harmonic Mitigation
<30% 0-100% Not required

>30% <90% <10% Not required
>30% <90% 10-100% Required*
>90% <10% Required*
>90% 10-100% Target 5% TDD
*Harmonic mitigation in accordance to IEEE 519-2014: Table 2

Part 1 completed, Thanks!
10min. Break
Part 1:
Part 2:

2.4 Open Discussion
Harmonics
What does a Harmonic current look like?

Harmonic Solutions for VSD - input current
Input current of a drive with 0,6% choke at 7kW load, 89%THDI
350,0 29,84
300,0 25,41
250,0 21,20
200,0 16,99
150,0 12,56
100,0 8,353
50,00 4,144
V 0,000 -0,286 A
-50,00 -4,495
-100,0 -8,704
-150,0 -13,13
-200,0 -17,34
-250,0 -21,55
-300,0 -25,76
-350,0 -30,19
17.01.2017 19,968 (ms) 17.01.2017
17:05:10.128 3 ms/Div 17:05:10.148
Input current of a drive with 1,8% choke at 7kW load, 51%THDI
350,0 21,91
300,0 18,87
250,0 15,66
200,0 12,62
150,0 9,571
100,0 6,365
50,00 3,320
V 0,000 0,115 A
-50,00 -2,931
-100,0 -5,976
-150,0 -9,181
-200,0 -12,23
-250,0 -15,43
-300,0 -18,48
-350,0 -21,52
16.01.2017 19,992 (ms) 16.01.2017
17:28:34.318 3 ms/Div 17:28:34.338
Input current of a drive with 5,4% (AC + DC) choke at 7kW load, 32%THDI
350,0 17,15
300,0 14,67
250,0 12,30
200,0 9,813
150,0 7,449
100,0 4,960
50,00 2,596
V 0,000 0,107 A
-50,00 -2,257
-100,0 -4,746
-150,0 -7,110
-200,0 -9,598
-250,0 -11,96
-300,0 -14,45
-350,0 -16,82
17.01.2017 19,988 (ms) 17.01.2017
17:29:43.142 3 ms/Div 17:29:43.162
Input current of a drive with RHF-8P filter at 7kW load, 7%THDI
350,0 16,86
300,0 14,45
250,0 12,04
200,0 9,752
150,0 7,341
100,0 4,930
50,00 2,518
V 0,000 0,107 A
-50,00 -2,183
-100,0 -4,594
-150,0 -7,005
-200,0 -9,417
-250,0 -11,83
-300,0 -14,12
-350,0 -16,53
17.01.2017 19,992 (ms) 17.01.2017
13:34:37.136 3 ms/Div 13:34:37.156
Input current of a drive with RHF-5P filter at 7kW load, 3.9%THDI
350,0 16,07
300,0 13,74
250,0 11,53
200,0 9,203
150,0 6,875
100,0 4,548
50,00 2,220
V 0,000 -0,107 A
-50,00 -2,319
-100,0 -4,646
-150,0 -6,974
-200,0 -9,301
-250,0 -11,63
-300,0 -13,96
-350,0 -16,28
17.01.2017 19,984 (ms) 17.01.2017
13:40:32.156 3 ms/Div 13:40:32.176
Harmonics
What kind of Harmonic Solutions are useful?

Harmonic Solutions for VSD - overview
Passive Active
Harmonic Harmonic
Filter Filter
Passive Active
solutions solutions
Low
12/18 Puls Active Front
Chokes Harmonic
Transformer End
Drives
ELTROPLAN-REVCON – company profile

Harmonic Solutions for VSD - overview
Line Inductance Passive Harmonic Active Frond End / Low Active Harmonic
Filter Harmonic Drive Filter
THDi THDi THDi THDi

~35-40% <10% <5% <5%
<5% Active
HF
Passive LCL
HF
uk==4% HF HF uk==4%
VFD VFD AFE / LHD VFD
M M M M
Harmonic Solutions for VSD - Choke
Solution DC or AC choke
THDi
~35-40% Value 4% impedance
Typical performance 35-50% THDi
Advantage Low costs
uk==4%
Disadvantage Low performance
VFD Recommended Yes, for small drives and
networks with much linear loads
This solution is very basic and usually inbuilt by factory

M inside the VSD. Therefore this is not considered as a
harmonic solution in the following presentation.
Harmonic Solutions for VSD - Passive HF
THDi Solution Passive Harmonic Filter

<10%
<5% Typical value n.a.
Passive Typical performance <5% or <10%
HF
HF Advantage Good cost/performace ratio
Disadvantage Significant different circuits and
VFD
products available.
Recommended Yes, if taking brand specific
specification such as
performance and efficiency
into account.
M
Harmonic Solutions for VSD - AFE and LHD
THDi Solution Active Front End Technology /

<5%
(ultra) Low Harmonic Drives*
LCL
Typical performance <5%
HF
Advantage Low THDi (<40th Harmonic)
Disadvantage Bad cost/performance ratio
AFE / LHD Low efficiency (high switching)
High distortion (>100th Harmonic)
Expensive
Low Lifetime expectance
No performance scaling
M Recommended No
*Some manufacturer have recognized the disadvantage of IGBT active infeed for
harmonic mitigation. Still the drive is considered as “low harmonic drive” but it use
internal passive filter or active filter. These solutions are recommended.
Harmonic Solutions for VSD - Active HF
Solution Active Harmonic Filter

THDi
<5% Typical performance <5%*
Active
HF Advantage High performance
Easy to retrofit in systems
uk==4% Can be used for universal load
Scalable for any performance
VFD High Efficiency
Disadvantage Medium price/performance
ratio
Some brand require expensive
commissioning
M Recommended Yes, especially in combination
with passive harmonic filter
*depend on filter size.

Harmonic Solutions for VSD - Active HF
Working principle Active Harmonic Filter
IGrid ILoad
~ LOAD
ICompensation
- =
Active Harmonic Filter are not sized by
Active line current, but by the compensation
current. For VFD applications Icompensation
HF is typically ~1/3 of drive input current.
𝐼𝐺𝑟𝑖𝑑 = 𝐼𝐿𝑜𝑎𝑑 − 𝐼𝐶𝑜𝑚𝑝𝑒𝑛𝑠𝑎𝑡𝑖𝑜𝑛
Harmonic Solutions for VSD - conclusion
What kind of Harmonic Solutions are useful?

Inductane Passive HF AFE or LHD Active HF Active and Passive HF
Low performance. Good performance to a Not recommend due to Recommend especially Often best technical and
Therefore not reasonable a price but high installation costs for retrofit and systems commercial solution.
considered as solution filter efficiency should and low efficiency. with many small drives Efficiency of the
be considered harmonic solutions
should be considered.
THDi THDi THDi THDi THDi

<1-5% Active
~35-40% <10% <5% <5%
Active HF
<5%
HF
Passive LCL
HF
uk==4% HF HF uk==4%
Passive
HF
HF
VFD VFD AFE / LHD VFD
VFD
VFD
M M M M M M
Part 1:
Part 2:

2.3 Hybrid Harmonic Filter / Hybrid Solution
2.4 Open Discussion
RHF - 5P and RHF-8P
RHF – 3rd Generation L1

L2
L3
Standard Compact Size PE
• Available from 1.1 – 280kW (400V) X1.1 X1.2 X1.3
• Two different performance levels [THDi]

L0
RHF-8P <8% (typ. test result 6,7%)
X2.1
X2.2
RHF-5P <5% (typ. test result 2,7%) X2.3
• High efficiency typically >99-99.5%

• Most efficient harmonic solution available
L1
• Core temperature supervision and fan control
• Improves (true) power factor (pf or l)
• Available for all common networks L2
• High lifetime expectation (typ. >15 Years)

RHF - high power range 2nd generation
L1
L2
L3
RHF – 3rd Generation

PE
High Power Split or Enclosed design

• Available up to 710kW (400V nom.) L0
• Available up to 1MW (690V nom.)

Mains inductance separated
• High efficiency typically 99,5%
• Two different performance levels [THDi] L1
RHF-5P <8% (typ. test result 6,7%)
RHF-B <5% (typ. test result 2,7%)
L2
• Most efficient harmonic solution available
• Core temperature supervision and fan control
• High lifetime expectation (typ. >15 Years)
Harmonics
A passive filter, is a passive filter. Right?

Benefits of the RHF
Benefit 1:
Performance
Benefit 2:
Efficiency
Benefit 3:
DC-Bus Level
Benefit 4:
Quality
Harmonic Solutions for VSD - Passive HF
Grid RHF Filter Load Setup RHF-8P: High Efficient Harmonic Filter
~ Typical THDi 6-8%
Circuit 2 – Stage Filter
Advantage Harmonic mitigation for all Harmonics
Disadvantage Higher production costs
Grid Simple PHF Load Setup Simple Passive Harmonic Filter
~ Typical THDi 10-12%
Advantage Cheap
Disadvantage Strong absorption only for 5th and 7th Harmonic.

Low absorption of 11th and 13th harmonic.
Very low absorption of high harmonics (>13th)
Simulation RHF (10%) vs. Simple-PHF (10%)
Grid RHF Filter Load
Grid Simple PHF Load
~
Simulation RHF (10%) vs. Simple-PHF (10%)
H23 H25 H29 H31

H35 H37 H41 H49
REMINDER:
6dB = ~50% Amplitude
H5 H7 H11 H13 H17 H19
Benefits of RHF
Harmonic Spectrum * THD with THD with THD with

(frequency band based on 50Hz fund. ) RHF-A/B Simple HF AFE
2nd – 7th Harmonic (100Hz - 350Hz) Very Low Very Low Very Low
2nd – 50th Harmonic (0,1kHz - 2,5kHz) Very Low Medium Very Low
50th – 200th Harmonic (2,5kHz – 10kHz) Very Low Medium High
*most common standards are only referring to harmonics up to 40 or 50.

Performance Guarantee Competitor
REVCON test conditions
25,0%
with RHF-A with RHF-B 5% Threshold Condition during test

20,0% Mains voltage +2-4%
V Unbalance 0.7 – 1.1%
15,0% Frequency +0.13Hz

THDi
Background THvD distortion 1.5-2%

10,0%
5,0%
0,0%
Motorload
Harmonic Solutions for 5% THDi
Grid RHF Filter Load Setup High Efficient Harmonic Filter
~ Possible THDi 2-5%
Advantage Harmonic mitigation for all Harmonics
Disadvantage Higher production costs
Typical PHF
Grid Load Setup Simple Passive Harmonic Filter “S-PHF”
~ Possible THDi 4-6%
Circuit 1 – Stage Filter with RC Circuit.
Advantage Lower Weight compared to 2-Stage
Disadvantage High Power Loss

Misleading Statements (from competitor)
Recommended requirement
“Note: Performance specification in this brochure refer to six pulse diode rectifier with 8% DC-link
choke. “
Hardware
Comment: There are no drives with 8% DC-link choke on the market. DC Bus decrease would be
significant and reduce drive performance
Performance „THiD ~5%“

Comment: ~ 5% = About 5%. This means can be 6-7%. Correct: <5%
Background THvD distortion 0%

Power Quality
Comment: this is not possible. Do not accept these kind of statements
“Helps/Supports to reach the IEEE519-2014”

Standards
Normally means you need further equipment to reach the standard.
Benefits of the RHF
THDi THDi performance as a function of load

12%
10%
8%
6%
4%
2%
0%
30% 40% 50% 60% 70% 80% 90% 100% 110% 120% 130% 140% 150%
Competitor 2 RHF-B 5% Load
 competitor products reach the required / stated values only under ideal conditions
Benefits of the RHF
Benefit 1:
Performance
Benefit 2:
Efficiency
Benefit 3:
DC-Bus Level
Benefit 4:
Quality
η of Harmonic Solutions - RHF
The efficiency of the Filter were measured with a Yokogawa high precision power meter WT 1800
100,0%
RHF-A
99,0%
RHF-B
98,0%
97,0%
96,0%
These Values were measured on the RHF 2nd Generation.

95,0%
Values in 3rd Generation Filter are typical + 0,25%
94,0%
10A 14A 22A 29A 34A 40A 55A 66A 82A 96A 133A 171A 204A 251A 304A 325A 381A 480A
ELTROPLAN-REVCON
η of Harmonic Solutions - 200A example
PLOSS = 3%
Active Front End /
LCL DC - Bus 97% efficiency
Low Harmonic Drive
PLOSS = 0.9% + 0.8% = 1.7%

Active Filter
+ B6 rectifier and DC - Bus 98,3% efficiency
4%
DC- choke
AF
High efficient PLOSS = 0.75% + 0.8% = 1.55%

Passive Harmonic Filter 98.45% efficiency
+ B6 rectifier and RHF DC - Bus
4%
DC- choke
PLOSS = 1.8-2.3% + 0.8% ≈ 2.85%

Simple
Passive Harmonic Filter 97.15% efficiency
PHF DC - Bus
+ B6 rectifier and 4%
DC- choke
* Assuming active filter sized for 30% of load current, filter efficiency of 97%.
η of Harmonic Solutions - 200kW example
𝟐𝟒𝐡 𝟑𝟔𝟓𝐝 𝟎,𝟏𝟓$

Calculation example for: 200kW Drive ; ;
𝐝 𝐚 𝐤𝐖𝐡
Efficiency RHF topology: η = 98.45%

Δη = 98.45% - 97% = -1.45%
Efficiency AFE topology: η = 97%
Annual energy savings:

24h 365d 24h 365d kWh
𝐸𝑠𝑎𝑣𝑒 = 𝑃𝐼𝑛𝑝𝑢𝑡 • Δη • • = 220kW • 0.0145 • • = 27 944
d a d a a
Annual cost savings:

kWh $ $
𝐶𝑠𝑎𝑣𝑒 = 𝐸𝑠𝑎𝑣𝑒 • 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑠𝑡 = 27 944 • 0.15 = 4 192
a kWh a
Benefits of the RHF
Benefit 1:
Performance
Benefit 2:
Efficiency
Benefit 3:
DC-Bus Level
Benefit 4:
Quality
Benefits of RHF
DC-Bus voltage DC-Bus voltage as a function of load

[%]
108%
106%
104%
102%
100%
98%
96%
94%
92%
90% Load
30% 40% 50% 60% 70% 80% 90% 100% 110% 120% 130% 140% 150% [%]
Competitor 2 RHF-B
 Higher DC bus voltage leads to better motor performance (full motor torque),
less IGBT losses and higher lifetime expectance.
Benefits of the RHF
Benefit 1:
Performance
Benefit 2:
Efficiency
Benefit 3:
DC-Bus Level
Benefit 4:
Quality
reasons to use the REVCON RHF
 Individual full load testing  True ISO 9001 : 2015

for each harmonic filter! certification
 Reliable PELV thermal  Corporate Social

protection Responsibility – our quality
management personnel
are ambassador of CSR
 High quality terminals with
defined connection torque
 Production in accordance
 Follows sustainable
to European quality
development goals of UN
standards
 ∑ RHF product failure = 0%

Harmonics
A passive filter, is a passive filter. Right?
Passive Harmonic Filter show some significant difference in internal setup.

This leads to difference in:
THDi Performance (higher order harmonics)

Efficiency (for 5% THDi Filters)
Drive Performance (DC-Bus level)
Quality (Terminals! Thermal Protection!)
Part 1:
Part 2:

2.3 Hybrid Harmonic Filter / Hybrid Solution
2.4 Open Discussion
Harmonics
What is the best Harmonic Solution?

Harmonic Solutions for VSD - System distortion
Pinput ≈ 750kW
THDiT = 11.24% THDi1 THDi2 THDi3 THDi4
1% 52% 35% 3,5%
The calculation of resulting

Passive
total grid THDi is very
uk==2% uk==4% HF
complex and considers the HF
phase angle of every
individual harmonic order.
VFD VFD VFD
These values were simulated
with Danfoss HCS.
The following calculation can

be used as a rough harmonic
result estimation.
M M M M
Different setups may cause
bigger result difference! P1 = 50kW P2 = 55kW P3 = 110kW P4 = 450kW
Project HK SST
N
PT = 2,187kW
THDiT = 3.3% THDi1 THDi2 THDi3
<10% 4.1% 3.2%
Passive Passive Passive

HF HF HF
HF HF HF
VFD VFD VFD
M M M
Total filter costs:
P1 = 36 x 0.75kW P2 = 32 x 3kW P3 = 2,032kW
100€ Single phase load Total 104 of different size
Project HK SST
N
PT = 2,187kW PT = 2,187kW
THDiT = 5% THDiT = 36% THDi1 THDi2 THDi3
80% 45% 35%
uk== 2% uk== 4%
VFD VFD VFD

10 x AHF 100A
Total filter
Line Current = 3,476A
costs:
Active Filter compensation current (simplified): M M M
121€
THDi reduction = THDi estimation – THDi target
THDi reduction = 36% - 5% = 31%
P1 = 36 x 0.75kW
Single phase load
P2 = 32 x 3kW P3 = 2,032kW
Total 104 of different size
Compenastion current = 1029A
(21% higher costs)
Project HK SST
N
PT = 2,187kW PT = 2,187kW
THDiT = 3% THDiT = 6% THDi1 THDi2 THDi3
<80% 45% 3.2%
Passive
uk==2% HF
HF
VFD VFD VFD

AHF 100A
Total filter costs:

Active Filter compensation current (simplified): M M M
Line Current = 3,476A
86€
THDi reduction = THDi estimation – THDi target
THDi reduction = 6% - 5% = 1%
P1 = 36 x 0.75kW
Single phase load
P2 = 32 x 3kW P3 = 2,032kW
Total 104 of different size
(savings 14%)
Compenastion current = 34,76A
Harmonics
What is the best Harmonic Solution?
All Harmonic Solutions have their advantages and disadvantages
Pure Passive Solution (good when many big loads)
Pure Active Solution (good for many small drives)
Hybrid (good for mix of big and small drives)
Active Front End (good for applications with regenerative power)

Part 1:
Part 2:

2.4 Open Discussion
RHF - Active
RHF-Active 100-400-50/60-20-A
• Advanced IGBT 3-Level topology
• Low losses = Compact size
44kg
• Power Loss 2078W max.
• Switching frequency 10-20kHz
• Unlimited parallel setup
50dm³
• Efficient Harmonic elimination up to 50th
• 99% system efficiency
Reactive Harmonics Unbalance

RHF - Active
RHF-Active 15-400-50/60-20-A
7kg
• SiC-Power MOSFET´s and Schottky
• Low losses = Compact size
8dm³
• System Efficiency 99,4% (based on 30% THDi Reduction)
• Unit Efficiency 98% @60kHz!
• High performance on strongly distorted load (e.g. 90% to 7%)
• High Performance on high order harmonics
• Noiseless!
Reactive Harmonics Unbalance

R Revcon references

Harmonic Distortion - Issues and Solutions

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Harmonic Distortion of Drives: Issues and Solutions

REVCON sales channel

2.1 Harmonic solutions available

Reactive current on fundamental frequency Voltage unbalance

Transients Harmonic distortion

Spectrum Individual frequencies Composed frequencies

The harmonic frequency is defined by:

Example for 𝑛 = 11 (11th harmonic) in a 50Hz network:

The harmonic current is the amplitude value of the corresponding frequency.

- Any signal can be expressed as a sum of its harmonics.

- The Fourier transform decomposes a function of

Harmonics are sinewave signals overlapping the main (fundamental)

Every Harmonic is defined by:

Harmonic order (5th Harmonic = 250Hz, 7th Harmonic = 350Hz … )

How are Harmonics evaluated?

THDi and THDv value

Flashback: what is the IRMS

Fundamental part Harmonic part

The THDi is defined as:

Drive input current

How are Harmonics evaluated?

Harmonic voltage distortion is evaluated by the THDv

2.1 Harmonic solutions available

Simple! That’s it?

THDi1 THDi2 THDi3 THDi4 THDi4 THDi0

VFD VFD VFD VFD AFE

Simple! That’s it?

Why do we care about Harmonic currents?

• Generators produce ideal sinusoidal current.

• --> No voltage distortion

ELTROPLAN-REVCON – company profile

• Generators produce (almost) ideal sinusoidal current.

• --> voltage distortion Ohm´s Law

Why do we care about Harmonic currents?

Voltage Distortion affects all equipment connected

Are all Harmonics equal?

THDi1 THDi2 THDi3 THDi4 THDi4 THDi0

VFD VFD VFD VFD AFE

Standard Drive vs. Slim DC Bus Drive

72,17 Arms, 31,10 %THD 34,63 Arms, 31,17 %THD

Power loss inside a transformer caused by I37

Power loss inside a motor caused by I37 would be

IEC define PWHD

Are all Harmonics equal?

Evaluation of Harmonic distortion based on THDi or TDD is only

Which damage is caused by harmonics?

Voltage distortion cause power loss!

@ 8% THDv, a motor DOL can run max. 85% load

Transformers and PFC

Motors and Generators (uncontrolled)

Which damage is caused by harmonics?

2.1 Harmonic solutions available

Do I need Harmonic mitigation?

Standard Class THDv limit

Practice - THDv limit

At full load: TDD = THDi

𝑆𝑆𝐶 𝐼𝑆𝐶 𝑅𝑆𝐶𝐸 : 𝑆ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑖𝑡 𝑝𝑜𝑤𝑒𝑟 𝑟𝑎𝑡𝑖𝑜

𝑍𝑠𝑐 : 𝑆ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑖𝑡 𝑖𝑚𝑝𝑒𝑑𝑎𝑛𝑐𝑒 (50Hz)

𝒁𝒔𝒄 : 𝑺𝒉𝒐𝒓𝒕 𝒄𝒊𝒓𝒄𝒖𝒊𝒕 𝒊𝒎𝒑𝒆𝒅𝒂𝒏𝒄𝒆 (50Hz)

𝒁𝒔𝒄 : 𝑺𝒉𝒐𝒓𝒕 𝒄𝒊𝒓𝒄𝒖𝒊𝒕 𝒊𝒎𝒑𝒆𝒅𝒂𝒏𝒄𝒆 (50Hz)

Do I need Harmonic mitigation?

<30% 0-100% Not required